Grid and Cell

Technologies for HDVs

EXPERT INTERVIEW WITH

Mustafa Karamuk
Senior R&D Engineer, Advanced Powertrain Systems
Ford Otosan
 Mustafa Karamuk
Electrical Engineer from Istanbul Technical University.
Since 2016, he has been studying towards Ph.D. degree
at Mechatronics Engineering Program at Istanbul Okan
University and has been working as senior R&D engineer
on electrification projects at Advanced Powertrain
Systems Department of Ford Otosan R&D Center in
Turkey.

In the lead-up to IQPC's Powertrain What other alternative

Electrification for HDVs Conference,
Mr. Karamuk discusses power grid
status and cell technology in terms
of latest developments and
challenges. He will hold a workshop
on Electric Logistics: Challenges and
Possibilities for HDVs used for
Goods and Transports,
The HDV segment is becoming
more electric. But what is the
current status of power grids?
EV charging impacts distribution
networks can be listed as voltage
regulation, harmonic distortion levels,
unbalances, additional losses and
transformers loss of lifetime. Therefore,
installation of fast chargers within the
same location can only be permitted
after analysis, feasibility of the
installed capacity and measurements.
Another critical issue for the HD fast
chargers is the simultaneous activation
of the multiple charging stations and
voltage drop, power harmonics impact
on the grid. Fast charging requires
constant high current for one hour
approx., which means constant loss,
voltage drop across the distribution
lines and also heating and extra
cooling for the distribution
transformers as well.
technologies could overcome the
power grid limitation?
Vehicle to grid (V2G) technologies which
enable bi-directional power between EVs
and grid can mitigate the limitation of the
installed grid power. Therefore, industry
leaders such as Siemens, ABB, Schneider
Electric have been developing solutions in
this field. Considering the power demand,
protection, safety and remote monitoring
requirements of the charging stations,
smart grid concept is the future trend that
can speed up the EV market.
The growth of EV market, specifically HD
segment, is tightly dependent on the high
power fast charging stations and increase
of charging stations at multiple points can
not be managed by the conventional grid
technologies. Therefore, EV market can be
expanded by the smart grid technologies.
"At -10 degrees, it may not be able
to climb a hill with 20 % grade until
the heater heats the battery and
allows the battery to deliver the
discharge current required at 20 %
grade."
 What are the challenges to be
overcome when it comes down
to cell technology?
The range and peak torque capability
of an EV varies depending on the
ambient temperature. The current cell
technology limits the battery discharge
and charge rates at temperatures
below 0. Practical consequences of the
current battery technologies in real life
conditions are the limitation of the
regenerative energy, power de-rating
and hence range.
At -10 degrees, it may not be able to
climb a hill with 20 % grade until the
heater heats the battery and allows the
battery to deliver the discharge current
required at 20 % grade. Vehicle range is
limited at low temperatures since the
regenerative energy is also limited due
to the limitation of the battery charge
current. Therefore, new cell
technologies are expected to improve
the battery performance at cold and
hot weather conditions which will
reduce the power requirement of the
thermal system that keeps the battery
pack within the permissible
temperature limits.
DO YOU WANT TO KNOW MORE ABOUT THE LATEST E-HDV TECHNOLOGY?
JULY 1 - 3 | Berlin, Germany
An alternative way could be the
development of more efficient thermal
systems for the batteries.
In summary, according to your
expertise, what are the main
requirements for each of the
technology fronts to further e-
HDV?
In terms of charging systems, Heavy Duty
Vehicles require high power charging
stations, which means higher impact on
grid power quality. As for the battery
technologies, the segment is in need of
high energy cells to increase the range
and optimise the total weight of the
battery pack. And this is where solid state
batteries can speed up the
commercialisation of HD vehicles. Now,
regarding thermal design, HDVs require
higher cooling power demand, more
auxiliary units which means increased
complexity. New thermal design
concepts are needed to manage the
complexity and optimise the system
efficiency -for example, Continental’s
new thermal system design given in the
materials.
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